BigDog Mowers C Series Parts Manual

Transcription

1 BigDog Mowers C Series Parts Manual 00 South Ridge Road Hesston, Kansas 6706

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3 Table of Contents General Information Service Literature Available From Your Dealer Using This Manual Hardware Description Codes & Abbreviations Standard Torques Section Frame S/N 0507 & Higher Frame S/N Prior to Engine Guard Section Hydraulic System Pump Belt Transmission Assembly Transmission Service Parts Steering Steering Sub-Assembly Park Brake Section 4 Wheel & Tire Front Wheel Breakdown Drive Wheel Breakdown Black Rim Drive Wheel Breakdown Chrome Rim Section 5 Engine, Briggs & Stratton 7.5/ HP S/N 0000 & Higher Fuel System, Briggs & Stratton 7.5/ HP S/N 0000 & Higher Engine, Briggs & Stratton 7.5/ HP S/N Prior to Fuel System, Briggs & Stratton 7.5/ HP S/N Prior to Engine Service Parts, Briggs 7.5 HP & HP Engine, Briggs & Stratton 6 HP S/N 0000 & Higher Fuel System, Briggs & Stratton 6 HP S/N 0000 & Higher Engine, Briggs & Stratton 6 HP S/N Prior to Fuel System, Briggs & Stratton 6 HP S/N Prior to Engine Service Parts, Briggs 6 HP Engine, Kaw FR54V & FR600V S/N 0000 & Higher Fuel System, Kaw FR54V & FR600V S/N 0000 & Higher Engine, Kaw FR54V & FR600V S/N Prior to Fuel System, Kaw FR54V & FR600V S/N Prior to Engine Service Parts, Kawasaki FR54V & FR600V Engine, Kaw FR65V S/N 0000 & Higher Fuel System, Kaw FR65V S/N 0000 & Higher Engine, Kaw FR65V S/N Prior to Fuel System, Kaw FR65V S/N Prior to EX_074 c-

4 Engine Service Parts, Kawasaki FR65V Fuel Tank & Fender S/N 0000 & Higher Fuel Tank & Fender S/N Prior to Fuel Tank Service Parts S/N Prior to Section 6 Battery Instrument Panel, 7 HP & HP Briggs & Stratton Instrument Panel, 6 HP Briggs & Stratton Instrument Panel, Kawasaki Section 7 4" Service Deck " Deck Pulleys & Spindles " Deck " Service Deck " Deck Pulleys & Spindles " Deck " Service Deck " Deck Pulleys & Spindles " Deck Deck Lift Deck Mounting Hardware Section 8 Seat c- 456EX_074

5 General Information This Manual covers BigDog C-Series models 948EX, 946EX, 9444EX, 945EX, 9469EX, 9477EX, 957EX, 9580EX & 9598EX. Service Literature PART NO. DESCRIPTION 604 OPERATOR S MANUAL 4495EX WARRANTY STATEMENT 0894BD SERVICE MANUAL Available From Your Dealer PART NO. DESCRIPTION PART NO. DESCRIPTION 609 4" MULCH KIT 9965 CATCHER, -BAG 4" & 46" 60 46" MULCH KIT 9986 CATCHER, -BAG 54" 6 54" MULCH KIT 077 LED LIGHT KIT 67 HOUR METER KIT 74 STEERING ARM EXTENSION KIT CONTAINMENT KIT ARM REST KIT Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give the model and serial number to your parts and service representative. Note: Items sold in bulk such as seals and hoses are sold by the foot. Using This Manual This manual is part of a service package for the BigDog mowers. Use of this manual in conjunction with other Big- Dog mower and component manuals will provide the information necessary to service and maintain BigDog mowers. This Parts Manual provides a complete parts listing for the unit. Use this manual when ordering parts. Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed necessary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see your BigDog dealer for current information and parts. The Service Manual is a service guide for use by Service Technicians. It provides the necessary information needed to perform normal maintenance requirements on these units. The Operator's Manual provides fundamental operational information and operational safety that is needed when operating the mower. The component manuals are furnished by the various manufacturers to be used for the troubleshooting and servicing of their products. 456EX_074 -

6 Hardware Description Codes & Abbreviations The following codes are used throughout this parts manual. Refer to this list when ordering parts. ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION CB CARRIAGE BOLT MB MACHINE BUSHING CE CLEVIS PIN MS MACHINE SCREW CN CLIP NUT NT NUT CP COTTER PIN SC SELF TAPPING CAP SCREW CS CAP SCREW SH SOCKET HEAD CW CUP WASHER SB SHOULDER BOLT FDRW FENDER WASHER SS SET SCREW FW FLAT WASHER OD OUTSIDE DIAMETER HX HEX HEAD ID INSIDE DIAMETER LW LOCK WASHER Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener. SIZE FT-LBS N-M SIZE FT-LBS N-M M.. 7 M M M M M M M M M M EX_074

7 Section Frame S/N 0507 & Higher Frame S/N Prior to Engine Guard EX_074 -

8 Frame S/N 0507 & Higher EX_074

9 Frame S/N 0507 & Higher INDEX NO. PART NO. QTY. DESCRIPTION " MOWER FRAME (WITH DECALS & RIVET NUTS) " MOWER FRAME (WITH DECALS & RIVET NUTS) " MOWER FRAME (WITH DECALS & RIVET NUTS) 60 BIG DOG LOGO DECAL 777 MADE IN USA DECAL SERIAL NUMBER / SPEC DECAL HOT DECAL ENGINE COMPARTMENT DECAL LS STEERING DECAL SAFE OPERATION DECAL PUMP BELT WARNING DECAL RS STEERING DECAL /6-8 THREAD RIVET NUT 60 C4 DECAL BUMPER (WITH DECAL) CS.75-6 X.5 HX G NT.75-6 HX FLK ZNYC NOTES:. Serial Number plate. In the event the serial number tag becomes damaged or illegible, please contact your dealer to order a replacement. 456EX_074 -

10 Frame S/N Prior to EX_074

11 Frame S/N Prior to 0507 INDEX NO. PART NO. QTY. DESCRIPTION " FRAME (WITH DECALS & RIVET NUTS) " FRAME (WITH DECALS & RIVET NUTS) " FRAME(WITH DECALS & RIVET NUTS) STEP TREAD /6-8 THREAD RIVET NUT RS STEERING DECAL PUMP BELT WARNING DECAL HOT DECAL ENGINE COMPARTMENT DECAL 8 N/A SERIAL NUMBER / SPEC DECAL LS STEERING DECAL MADE IN USA DECAL 60 BIG DOG LOGO DECAL 6099 SAFE OPERATION DECAL 60 C4 DECAL 60 C46 DECAL 6075 C54 DECAL 4 60 STEP TREAD NOTES:. In the event the serial number tag becomes damaged or illegible, please contact your dealer to order a replacement. 456EX_074-5

12 Engine Guard 4 INDEX NO. PART NO. QTY DESCRIPTION BUMPER GUARD PLATE 0648 CS.75-6 X.50 HX G FW.406 X.8 X.060 SAE NT.75-6 HXZY NL NOTES: EX_074

13 Section Hydraulic System Pump Belt Transmission Assembly Transmission Service Parts Steering Steering Sub-Assembly Park Brake EX_074 -

14 Hydraulic System EX_074

15 Hydraulic System INDEX NO. PART NO. QTY. DESCRIPTION CS.-8 X.50 HX G CS.-8 X.00 HX G5 Z FW.4 X.687 X.05/.080H TOWLINK ROD CP.06D X.00 LG HML Z 6 N/A TRANSMISSION ASSEMBLY NT 0.-8 HX G5. Torque to 7 ft-lbs. NOTES: 456EX_074 -

16 Pump Belt EX_074

17 Pump Belt INDEX NO. PART NO. QTY. DESCRIPTION CS.500- X.75 HX G CS.65- X.5 HX G5 ZY FW.65 X.00 X.4 ZNYC 0684 SPRING /4 COIL PL. 079 PUMP IDLER 6006 BEARING DISC BUSHING NT.500- HX G8 ZY NL IDLER SPACER IDLER PULLEY 4.00" OD NT.65- HX G5 ZNYC BELT. Torque to 00 ft-lbs. NOTES: 456EX_074-5

18 Transmission Assembly EX_074

19 Transmission Assembly INDEX NO. PART NO. QTY. DESCRIPTION CS.75-6 X.5 HX G5 004 HYDROSTAT CROSS BRACE FW.406 X.8 X.060 SAE NT.75-6 HX G5 ZNY RS TRANSMISSION LS TRANSMISSION BRAKE ACTUATOR ROD NT.50-0 HX ZY NL FW.8 X.65 X.05/.080H 0 60 SPRING NOTES: 456EX_074-7

20 Transmission Service Parts INDEX NO. PART NO. QTY. DESCRIPTION 6094 FAN/PULLEY KIT BOLT HUB KIT (INCLUDES NUT) HUB NUT RETAINING RING PARK BRAKE GEAR PARKING PAWL KIT NOTES: EX_074

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22 Steering STEERING SUB-ASSEMBLY EX_074

23 Steering INDEX NO. PART NO. QTY. DESCRIPTION 600 STEERING DAMPER BALL STUD FW.4 X.687 X.05/.080H NT.-4 HX ZY NL LOCK COLLAR ID PUMP ROD NT.-8 HX G5 ZNYC CS.-8 X.75 HX G PIVOT TUBE LW. INT-EXT TOOTH 6046 CAP LOCK NOTES: 456EX_074 -

24 Steering Sub-Assembly LEFT SIDE SHOWN RIGHT SIDE SIMILAR EX_074

25 Steering Sub-Assembly INDEX NO. PART NO. QTY. DESCRIPTION 7860 STEERING BAR GRIP 070 STEERING BAR (WITH GRIP) NT.75-6 HX G5 ZNY FW.79 X.8 X.06 SAE CONTROL LEVER CS.75-6 X.50 BH BO BALL JOINT LINK NT.-4 HX NL ZN BUSHING CS.75-6 X.75 HX G FW.4 X.687 X.05/.080H NT.75-6 HX NL G LS STEERING BOX 0007 RS STEERING BOX (NOT SHOWN) NOTES: 456EX_074 -

26 Park Brake 0 RIGHT SIDE SHOWN LEFT SIDE SIMILAR 6 BALL JOINT LINK EX_074

27 Park Brake INDEX NO. PART NO. QTY. DESCRIPTION 000 LS BRAKE ACTUATOR 0000 RS BRAKE ACTUATOR BUSHING NUT PLATE.40 CENTERS 5 78 PUSH BUTTON SWITCH NT.75-6 HX ZY NL FW.406 X.8 X.060 SAE CS.75-6 X 4.00 HX G8 Z CS 0-4 X.75 HXFLK ZN CP.06D X.00 LG HML Z FW.4 X.687 X.05/.080H 0655 NT.-4 HX ZY NL 0009 BRAKE ACTUATOR ROD NT.50-0 HXZY NL FW.8 X.65 X.05/.080H 6 60 SPRING. Part of the wire harness. NOTES: 456EX_074-5

28 -6 456EX_074

29 Section 4 Wheel & Tire Front Wheel Breakdown Drive Wheel Breakdown Black Rim Drive Wheel Breakdown Chrome Rim EX_074 4-

30 Wheel & Tire EX_074

31 Wheel & Tire INDEX NO. PART NO. QTY. DESCRIPTION PLASTIC WHEEL ASSEMBLY (WITH HARDWARE) FW.50 X.5 X.87 SPL NT.500- NL G TIRE/WHEEL 8 X (BLACK RIMS 4" & 46" DECKS) 6080 TIRE/WHEEL 8 X (CHROME RIMS 4" & 46" DECKS) 6055 TIRE/WHEEL 8 X (BLACK RIMS 54" DECKS) TIRE/WHEEL 8 X (CHROME RIMS 54" DECKS) WHEEL NUT CS.500- X.5 HS G FW.5 X.75 X BEARING SPACER 0 N/A FRONT WHEEL SUB-ASSEMBLY CS.500- X 4.5 HX G FW.5 X.06 X.090 SAE 0997 PLASTIC WHEEL NT.500- HX JAM ZNYC. Torque to ft-lbs. NOTES: 456EX_074 4-

32 Front Wheel Breakdown EX_074

33 Front Wheel Breakdown INDEX NO. PART NO. QTY. DESCRIPTION 9006 CASTER FORK NT.500- HX G8 ZY NL FW.5 X.06 X.090 SAE CS.500- X 6.50 HX G5 Z GAUGE WHEEL SPACER TIRE/WHEEL X 4-5 (SMOOTH) TIRE/WHEEL X 4-5 (RIBBED) BEARING CAP /4" ROLLER BEARING NOTES: 456EX_

34 Drive Wheel Breakdown Black Rim TIRE/WHEEL ASSEMBLY (4" & 46" DECKS) INDEX NO. PART NO. QTY. DESCRIPTION TIRE 8 X WHEEL 8 X TIRE VALVE 6055 TIRE/WHEEL ASSEMBLY (54" DECKS) INDEX NO. PART NO. QTY DESCRIPTION 7847 TIRE 8 X WHEEL 8.00 X TIRE VALVE NOTES: EX_074

35 Drive Wheel Breakdown Chrome Rim 6080 TIRE/WHEEL ASSEMBLY (4" & 46" DECKS) INDEX NO. PART NO. QTY. DESCRIPTION 608 TIRE 8 X WHEEL 8 X TIRE VALVE TIRE/WHEEL ASSEMBLY (54" DECKS) INDEX NO. PART NO. QTY DESCRIPTION 7847 TIRE 8 X WHEEL 8.00 X TIRE VALVE NOTES: 456EX_

36 EX_074

37 Section 5 Engine, Briggs & Stratton 7.5/ HP S/N 0000 & Higher Fuel System, Briggs & Stratton 7.5/ HP S/N 0000 & Higher Engine, Briggs & Stratton 7.5/ HP S/N Prior to Fuel System, Briggs & Stratton 7.5/ HP S/N Prior to Engine Service Parts, Briggs 7.5 HP & HP Engine, Briggs & Stratton 6 HP S/N 0000 & Higher Fuel System, Briggs & Stratton 6 HP S/N 0000 & Higher Engine, Briggs & Stratton 6 HP S/N Prior to Fuel System, Briggs & Stratton 6 HP S/N Prior to Engine Service Parts, Briggs 6 HP Engine, Kaw FR54V & FR600V S/N 0000 & Higher Fuel System, Kaw FR54V & FR600V S/N 0000 & Higher Engine, Kaw FR54V & FR600V S/N Prior to Fuel System, Kaw FR54V & FR600V S/N Prior to Engine Service Parts, Kawasaki FR54V & FR600V Engine, Kaw FR65V S/N 0000 & Higher Fuel System, Kaw FR65V S/N 0000 & Higher Engine, Kaw FR65V S/N Prior to Fuel System, Kaw FR65V S/N Prior to Engine Service Parts, Kawasaki FR65V Fuel Tank & Fender S/N 0000 & Higher Fuel Tank & Fender S/N Prior to Fuel Tank Service Parts S/N Prior to EX_074 5-

38 Engine, Briggs & Stratton 7.5/ HP S/N 0000 & Higher 9 0 RED RED TO BATTERY BLK A FUSE 6 7 PART OF ENGINE EX_074

39 Engine, Briggs & Stratton 7.5/ HP S/N 0000 & Higher INDEX NO. PART NO. QTY. DESCRIPTION N/A BRIGGS & STRATTON 7.5/ HP ENGINE 6006 SC # 8 X.00 PHCR BO BRIGGS CONTACT COVER NT.-8 HX G5 ZNYC FW.4 X.687 X.05/.080H NEGATIVE BATTERY CABLE LW. INT-EXT TOOTH RED BATTERY CABLE BOOT NT.50-0 HX G5 ZNYC FW.8 X.65 X.05/.080H 6006 POSITIVE BATTERY CABLE POSITIVE BATTERY CABLE NT #0- HX ZN CS.50-0 X.75 HX G STARTER SOLENOID OIL DRAIN - /8-8 NPTF " OIL DRAIN HOSE CN.50-0 X.5 MAX THK CS.-8 X.75 HX G KEY /4 SQ X 0.66 LG ENGINE PULLEY 6080K CLUTCH KIT (WITH PIGTAIL) 795 CLUTCH HARNESS PIGTAIL FW.45 X. X.9 HRD CS.47-0 X.5 HX G5 P85 NOTES:. Part of the wire harness.. The pigtail is supplied with the clutch.. Torque the bolt to ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener. 456EX_074 5-

40 Fuel System, Briggs & Stratton 7.5/ HP S/N 0000 & Higher A FUEL FILTER 7 B INDEX NO. PART NO. QTY. DESCRIPTION WIRE TIE " /4" FUEL LINE HOSE CLAMP NOTES: A B FUEL & VAPOR LINE LENGTHS 9" TANK TO FUEL FILTER (FUEL) " FUEL FILTER TO ENGINE (FUEL) EX_074

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42 Engine, Briggs & Stratton 7.5/ HP S/N Prior to RED 9 0 RED BLK TO BATTERY 5A FUSE EX_074

43 Engine, Briggs & Stratton 7.5/ HP S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION N/A BRIGGS & STRATTON 7.5/ HP ENGINE 6006 SC # 8 X.00 PHCR BO BRIGGS CONTACT COVER NT.-8 HX G5 ZNYC FW.4 X.687 X.05/.080H NEGATIVE BATTERY CABLE LW. INT-EXT TOOTH RED BATTERY CABLE BOOT NT.5-0 HX GR.5 ZNYC FW.8 X.65 X.05/.080H 6006 POSITIVE BATTERY CABLE POSITIVE BATTERY CABLE NT #0- HX ZN CS.5-0 X.75 HX G STARTER SOLENOID OIL DRAIN - /8-8 NPTF OIL DRAIN HOSE CN.50-0 X.5 MAX THK CS.-8 X.75 HX G KEY /4 SQ X 0.66 LG ENGINE PULLEY 6080K CLUTCH KIT (WITH PIGTAIL) 795 CLUTCH HARNESS PIGTAIL FW.45 X. X.9 HRD CS.47-0 X.5 HXG5P85 NOTES:. Part of the wire harness.. The pigtail is supplied with the clutch.. Torque the bolt to ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener. 456EX_

44 Fuel System, Briggs & Stratton 7.5/ HP S/N Prior to B FUEL FILTER A 4 D E 7 C EX_074

45 Fuel System, Briggs & Stratton 7.5/ HP S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION 6 60 CLAMP, /6" " /6" VAPOR LINE PLASTIC TEE /4" X /4" X /6" HOSE CLAMP CS.75-6 X.00 HX G LOOP CLAMP 608 VACUUM BREAKER WIRE TIE, SMALL/SHORT " /4" FUEL LINE NT.75-6 HXFLK ZNYC FW.406 X.8 X.060 SAE VACUUM BREAKER FILTER NOTES: A B C D E FUEL & VAPOR LINE LENGTHS 9" TANK TO FUEL FILTER (FUEL) " TANK TO TEE (VAPOR) " TEE TO VACUUM BREAKER (VAPOR) " FUEL FILTER TO ENGINE (FUEL) " ENGINE TO TEE (VAPOR) 456EX_

46 Engine Service Parts, Briggs 7.5 HP & HP 4 INDEX NO. PART NO. QTY. DESCRIPTION IN-LINE FUEL FILTER AIR PRECLEANER FILTER, FLAT PANEL (7.5 HP) AIR PRECLEANER FILTER ( HP) AIR FILTER, FLAT PANEL (7.5 HP) AIR FILTER, CARTRIDGE ( HP) OIL FILTER NOTES: EX_074

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48 Engine, Briggs & Stratton 6 HP S/N 0000 & Higher EX_074

49 Engine, Briggs & Stratton 6 HP S/N 0000 & Higher INDEX NO. PART NO. QTY. DESCRIPTION N/A BRIGGS & STRATTON 6 HP ELS ENGINE 6006 SC # 8 X.00 PHCR BO 604 STATIC COVER ASSEMBLY OIL DRAIN - /8-8 NPTF " OIL DRAIN HOSE MUFFLER SC.75-6 X.0 HX FL STP WIRE TIE CLUTCH HARNESS PIGTAIL 0 77 KEY /4 SQ X 0.66 LG ENGINE PULLEY 60784K CLUTCH KIT (WITH PIGTAIL) FW.45 X. X.9 HRD CS.47-0 X.50 HX G5 P85 NOTES:. Torque to ft-lbs. Replace (do not reuse) the cap screw if it is removed or loosened. Use only hand tools to install this fastener.. Torque to 0 ft-lbs.. Supplied with the engine. 4. Torque to 7.5 ft-lbs. 456EX_074 5-

50 Engine, Briggs & Stratton 6 HP S/N 0000 & Higher 5 5A FUSE RED 5 5 BLK EX_074

51 Engine, Briggs & Stratton 6 HP S/N 0000 & Higher INDEX NO. PART NO. QTY. DESCRIPTION RED BATTERY CABLE BOOT NT.50-0 HX G5 ZNYC FW.8 X.65 X.05/.080H POSITIVE BATTERY CABLE STARTER SOLENOID POSITIVE BATTERY CABLE NT #0- HX ZN CS.50-0 X.75 HX G5 047 NT.-8 HX G5 ZNYC FW.4 X.687 X.05/.080H LW. INT-EXT TOOTH NEGATIVE BATTERY CABLE CN.50-0 X.5 MAX THK CS.-8 X.75 HX G5 5. Part of the wire harness. NOTES: 456EX_

52 Fuel System, Briggs & Stratton 6 HP S/N 0000 & Higher 0 9 A 8 0 INDEX NO. PART NO. QTY. DESCRIPTION " /4" FUEL LINE HOSE CLAMP NOTES: FUEL LINE LENGTHS A 8" TANK TO ENGINE (FUEL) EX_074

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54 Engine, Briggs & Stratton 6 HP S/N Prior to EX_074

55 Engine, Briggs & Stratton 6 HP S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION N/A BRIGGS & STRATTON 6 HP ELS ENGINE 6006 SC # 8 X.00 PHCR BO 604 STATIC COVER ASSEMBLY OIL DRAIN - /8-8 NPTF OIL DRAIN HOSE MUFFLER SC.75-6 X.0 HX FL STP WIRE TIE CLUTCH HARNESS PIGTAIL 0 77 KEY /4 SQ X 0.66 LG ENGINE PULLEY 60784K CLUTCH KIT (WITH PIGTAIL) FW.45 X. X.9 HRD CS.47-0 X.5 HX G5 P85 NOTES:. Torque to ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener.. Torque to 0 ft-lbs.. Supplied with the engine. 4. Torque to 7.5 ft-lbs. 456EX_

56 Engine, Briggs & Stratton 6 HP S/N Prior to A FUSE RED BLK EX_074

57 Engine, Briggs & Stratton 6 HP S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION RED BATTERY CABLE BOOT NT.50-0 HX G5 ZNYC FW.8 X.65 X.05/.080H POSITIVE BATTERY CABLE STARTER SOLENOID POSITIVE BATTERY CABLE NT #0- HX ZN CS.50-0 X.75 HX G5 047 NT.-8 HX G5 ZNYC FW.4 X.687 X.05/.080H LW. INT-EXT TOOTH NEGATIVE BATTERY CABLE CN.50-0 X.5 MAX THK CS.-8 X.75 HX G5 5. Part of the wire harness. NOTES: 456EX_074 5-

58 Fuel System, Briggs & Stratton 6 HP S/N Prior to 0000 A B C D EX_074

59 Fuel System, Briggs & Stratton 6 HP S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION " /4" FUEL LINE HOSE CLAMP LOOP CLAMP 608 VACUUM BREAKER 6005 PLASTIC TEE /4" X /4" X /6" " /6" VAPOR LINE CS.75-6 X.00 HX G CLAMP, /6" NT.75-6 HX FLK ZNYC FW.406 X.8 X.060 SAE VACUUM BREAKER FILTER NOTES: FUEL LINE LENGTHS A B C D " TANK TO TEE (VAPOR) " TEE TO VACUUM BREAKER (VAPOR) 8" TANK TO ENGINE (FUEL) 40" TEE TO ENGINE (VAPOR) 456EX_074 5-

60 Engine Service Parts, Briggs 6 HP 4 INDEX NO. PART NO. QTY. DESCRIPTION 6057 AIR PRECLEANER FILTER AIR FILTER, CARTRIDGE IN-LINE FUEL FILTER OIL FILTER NOTES: EX_074

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62 Engine, Kaw FR54V & FR600V S/N 0000 & Higher RED 5 RED A FUSE 9 0 BLK EX_074

63 Engine, Kaw FR54V & FR600V S/N 0000 & Higher INDEX NO. PART NO. QTY. DESCRIPTION N/A KAWASAKI FR54V/FR600V ENGINE NT.75-6 HX FLK ZNYC 970 CABLE GUIDE LOOP CLAMP FW.406 X.8 X.060 SAE CS.75-6 X.00 HX G CS M8 X.5 X 6 HX G FW.4 X.687 X.05/.080H NEGATIVE BATTERY CABLE LW. INT-EXT TOOTH 7748 RED BATTERY CABLE BOOT 0497 NT.50-0 HX G5 ZNYC FW.8 X.65 X.05/.080 HD ZN/YL POSITIVE BATTERY CABLE POSITIVE BATTERY CABLE NT #0- HX ZN CS.50-0 X.75 HX G STARTER SOLENOID MUFFLER CN.50-0 X.5 MAX THK CS.75-6 X.5 HX G5 P ENGINE PULLEY 77 KEY /4 SQ X 0.66 LG K CLUTCH KIT (WITH PIGTAIL) CLUTCH HARNESS PIGTAIL FW.45 X. X.9 HRD CS.47-0 X.5 HX G5 P OIL DRAIN VALVE " OIL DRAIN HOSE NOTES:. Part of the wire harness.. Supplied with the engine.. Torque the bolt to ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener. 4. Torque the bolt to 0 5 ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener. 5. Torque the nut to ft-lbs. 456EX_

64 Fuel System, Kaw FR54V & FR600V S/N 0000 & Higher 0 A 0 INDEX NO. PART NO. QTY. DESCRIPTION HOSE CLAMP " /4" FUEL LINE NOTES: FUEL LINE LENGTHS A 5" TANK TO FUEL FILTER (FUEL) EX_074

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66 Engine, Kaw FR54V & FR600V S/N Prior to 0000 RED/BLK 6 4 5A FUSE RED BLK EX_074

67 Engine, Kaw FR54V & FR600V S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION N/A KAWASAKI FR54V & FR600V ENGINE 970 CABLE GUIDE LOOP CLAMP CS.75-6 X.00 HX G FW.4 X.687 X.05/.080H NT.75-6 HX FLK ZNYC CS M8 X.5 X 6 HX G MUFFLER LW. INT-EXT TOOTH NEGATIVE BATTERY CABLE 7748 RED BATTERY CABLE BOOT 0497 NT.50-0 HX G5 ZNYC FW.8 X.65 X.05/.080H POSITIVE BATTERY CABLE CS.50-0 X.75 HX G NT #0- HX ZN STARTER SOLENOID POSITIVE BATTERY CABLE WIRE TIE CN.50-0 X.5 MAX THK FW.406 X.8 X.060 SAE CS.75-6 X.5 HX G5 P ENGINE PULLEY 4 77 KEY /4 SQ X 0.66 LG K CLUTCH KIT (WITH PIGTAIL) CLUTCH HARNESS PIGTAIL FW.45 X. X.9 HRD CS.47-0 X.5 HX G5 P OIL DRAIN VALVE " OIL DRAIN HOSE NOTES:. Part of the wire harness.. Supplied with the engine.. Torque to ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener. 4. Torque to 0 5 ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener. 5. Torque to ft-lbs. 456EX_074 5-

68 Fuel System, Kaw FR54V & FR600V S/N Prior to 0000 A B C 4 D EX_074

69 Fuel System, Kaw FR54V & FR600V S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION 000 HOSE CLAMP 60 CLAMP, /6" " /4" FUEL LINE " /6" VAPOR LINE PLASTIC TEE, /6" VACUUM BREAKER VACUUM BREAKER FILTER NOTES: FUEL & VAPOR LINE LENGTHS A B C D 5" TANK TO FUEL FILTER (FUEL) " TANK TO TEE (VAPOR) " TEE TO VACUUM BREAKER (VAPOR) 4" TEE TO ENGINE PURGE PORT (VAPOR) 456EX_074 5-

70 Engine Service Parts, Kawasaki FR54V & FR600V INDEX NO. PART NO. QTY. DESCRIPTION AIR FILTER IN-LINE FUEL FILTER 6058 ENGINE OIL FILTER NOTES: EX_074

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72 Engine, Kaw FR65V S/N 0000 & Higher RED/BLK RED A FUSE BLK EX_074

73 Engine, Kaw FR65V S/N 0000 & Higher INDEX NO. PART NO. QTY. DESCRIPTION N/A KAWASAKI FR65V ENGINE 970 CABLE GUIDE LOOP CLAMP CS.75-6 X.00 HX G FW.4 X.687 X.05/.080H NT.75-6 HX FLK ZNYC CS M8 X.5 X 6 HX G MUFFLER LW. INT-EXT TOOTH NEGATIVE BATTERY CABLE 7748 RED BATTERY CABLE BOOT 0497 NT.50-0 HX G5 ZNYC FW.8 X.65 X.05/.080 HD ZN/YL POSITIVE BATTERY CABLE CS.50-0 X.75 HX G NT #0- HX ZN STARTER SOLENOID POSITIVE BATTERY CABLE CN.50-0 X.5 MAX THK FW.406 X.8 X.060 SAE CS.75-6 X.5 HX G5 P ENGINE PULLEY 77 KEY /4 SQ X 0.66 LG K CLUTCH KIT CLUTCH HARNESS PIGTAIL FW.45 X. X.9 HRD CS.47-0 X.5 HX G5 P OIL DRAIN VALVE " HOSE, 0.50" LOW PRESSURE WIRE TIE NOTES:. Part of the wire harness.. Supplied with the engine.. Torque to ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener. 4. Torque to 0 5 ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener. 5. Torque to ft-lbs. 456EX_

74 Fuel System, Kaw FR65V S/N 0000 & Higher A INDEX NO. PART NO. QTY. DESCRIPTION " /4" FUEL LINE HOSE CLAMP NOTES: FUEL LINE LENGTHS A 5" TANK TO FUEL FILTER (FUEL) EX_074

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76 Engine, Kaw FR65V S/N Prior to A FUSE 5 RED/BLK RED BLK EX_074

77 Engine, Kaw FR65V S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION N/A KAWASAKI FR65V ENGINE 970 CABLE GUIDE LOOP CLAMP CS.75-6 X.00 HX G FW.4 X.687 X.05/.080H NT.75-6 HX FLK ZNYC CS M8 X.5 X 6 HX G MUFFLER LW. INT-EXT TOOTH NEGATIVE BATTERY CABLE 7748 RED BATTERY CABLE BOOT 0497 NT.50-0 HX G5 ZNYC FW.8 X.65 X.05/.080H POSITIVE BATTERY CABLE CS.50-0 X.75 HX G NT #0- HX ZN STARTER SOLENOID POSITIVE BATTERY CABLE CN.50-0 X.5 MAX THK FW.406 X.8 X.060 SAE CS.75-6 X.5 HX G5 P ENGINE PULLEY 77 KEY /4 SQ X 0.66 LG K CLUTCH KIT (WITH PIGTAIL) CLUTCH HARNESS PIGTAIL FW.45 X. X.9 HRD CS.47-0 X.5 HX G5 P OIL DRAIN VALVE " OIL DRAIN HOSE WIRE TIE NOTES:. Part of the wire harness.. Supplied with the engine.. Torque to ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener. 4. Torque to 0 5 ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener. 5. Torque to ft-lbs. 456EX_

78 Fuel System, Kaw FR65V S/N Prior to 0000 A B 4 0 D 7 0 C EX_074

79 Fuel System, Kaw FR65V S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION HOSE CLAMP 60 CLAMP, /6" 6005 PLASTIC TEE /4" X /4" X /6" LOOP CLAMP VACUUM BREAKER " /4" FUEL LINE " /6" VAPOR LINE VACUUM BREAKER FILTER NOTES: FUEL & VAPOR LINE LENGTHS A B C D 5" TANK TO ENGINE (FUEL) " TANK TO TEE (VAPOR) " TEE TO VACUUM BREAKER (VAPOR) 4" TEE TO ENGINE (VAPOR) 456EX_

80 Engine Service Parts, Kawasaki FR65V INDEX NO. PART NO. QTY. DESCRIPTION AIR FILTER IN-LINE FUEL FILTER 6058 ENGINE OIL FILTER NOTES: EX_074

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82 Fuel Tank & Fender S/N 0000 & Higher EX_074

83 Fuel Tank & Fender S/N 0000 & Higher INDEX NO. PART NO. QTY. DESCRIPTION FUEL CAP,.5" 6076 RS FENDER 6077 LS FUEL TANK FW.4 X.687 X.05/ CS.-8 X.750 HX G FLANGE GROMMET SUCTION HOSE ASSY 0.5". Torque to 7 ft-lbs. NOTES: 456EX_

84 Fuel Tank & Fender S/N Prior to EX_074

85 Fuel Tank & Fender S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION 6076 RS FENDER 6050 LS TANK FENDER ASSEMBLY RATCHETING GAS CAP,.5" FW.4 X.687 X.05/.080H CS.-8 X.750 HX G5. Torque to 7 ft-lbs. NOTES: 456EX_

86 Fuel Tank Service Parts S/N Prior to S/N Prior to 0000 S/N INDEX NO. PART NO. QTY. DESCRIPTION 78 VENT FITTING KIT SUCTION HOSE ASSEMBLY 0.5" GROMMET NOTES: EX_074

87 Section 6 Battery Instrument Panel, 7 HP & HP Briggs & Stratton Instrument Panel, 6 HP Briggs & Stratton Instrument Panel, Kawasaki EX_074 6-

88 Battery POSITIVE CABLE (RED) NEGATIVE CABLE (BLACK) EX_074

89 Battery INDEX NO. PART NO. QTY. DESCRIPTION 6090 CS.50-0 X 6.50 HX G FW.8 X.65 X.05/.080H 4847 BATTERY CLAMP STRAP CS.50-0 X.75 HX G5 ZN LW.50 INT-EXT TOOTH Z NT.50-0 HX G5 ZNYC RED BATTERY CABLE BOOT CN.50-0 X.5 MAX THK GROMMET WIRE TIE NOTES: 456EX_074 6-

90 Instrument Panel, 7 HP & HP Briggs & Stratton EX_074

91 Instrument Panel, 7 HP & HP Briggs & Stratton INDEX NO. PART NO. QTY. DESCRIPTION PTO SWITCH KEY ASSEMBLY IGNITION SWITCH SEALED RELAY (WITH BRACKET) CB 0-4 X.50 ZYNC WIRE TIE THROTTLE/CHOKE CABLE FW.9 X.50 X.048 ZNYC NT #0-4 HX NL ZN FW.8 X.65 X.05/.080H CS.50-0 X.50 HX G INSTRUMENT PANEL (WITH DECAL) 608 INSTRUMENT PANEL DECAL WIRE HARNESS CLUTCH CONNECTOR REPAIR KIT. Part of the wire harness. NOTES: 456EX_

92 Instrument Panel, 6 HP Briggs & Stratton EX_074

93 Instrument Panel, 6 HP Briggs & Stratton INDEX NO. PART NO. QTY. DESCRIPTION PTO SWITCH KEY ASSEMBLY IGNITION SWITCH CB 0-4 X.50 ZYNC WIRE TIE " THROTTLE/CHOKE CABLE FW.9 X.50 X.048 ZNYC NT #0-4 HX NL ZN FW.8 X.65 X.05/.080H CS.50-0 X.50 HX G INSTRUMENT PANEL (WITH DECAL) 608 INSTRUMENT PANEL DECAL WIRE HARNESS SEALED RELAY (WITH BRACKET) CLUTCH CONNECTOR REPAIR KIT. Part of the wire harness. NOTES: 456EX_

94 Instrument Panel, Kawasaki EX_074

95 Instrument Panel, Kawasaki INDEX NO. PART NO. QTY. DESCRIPTION CHOKE CABLE PTO SWITCH KEY ASSEMBLY IGNITION SWITCH SEALED RELAY (WITH BRACKET) CB 0-4 X.50 ZYNC WIRE TIE THROTTLE CABLE FW.9 X.50 X.048 ZNYC NT #0-4 HX NL ZN CS.50-0 X.50 HX G FW.8 X.65 X.05/.080H 6009 INSTRUMENT PANEL DECAL INSTRUMENT PANEL (WITH DECAL) WIRE HARNESS CLUTCH CONNECTOR REPAIR KIT. Part of the wire harness. NOTES: 456EX_

96 EX_074

97 Section 7 4" Service Deck " Deck Pulleys & Spindles " Deck " Service Deck " Deck Pulleys & Spindles " Deck " Service Deck " Deck Pulleys & Spindles " Deck Deck Lift Deck Mounting Hardware EX_074 7-

98 4" Service Deck EX_074

99 4" Service Deck INDEX NO. PART NO. QTY DESCRIPTION " DECK (WITH DECALS & HARDWARE) CN.-8 X.00 MAX THK 6064 DISCHARGE CHUTE DECAL DECK DANGERS DECAL THROWN OBJECTS DECAL BELT ROUTING DECAL NOTES: 456EX_074 7-

100 4" Deck Pulleys & Spindles EX_074

101 4" Deck Pulleys & Spindles INDEX NO. PART NO. QTY DESCRIPTION CS.65- X.50 HX G FW.656 X.00 X.078 ZNYC FW.650 X.5 X.8 ZNYC G IDLER PULLEY 5.0" OD IDLER SLIDE SPRING /4 COIL PL CHAIN, LINK CS.-8 X.5 FLT SH IDLER SLIDE UHMW CS.500- X.5 HS G CS.65- X.5 HX G5 Z FW.55 X.65 X.5 HD ZY CW.6 X.5 X.87 PNT DECK SPINDLE PULLEY NT.75-6 HX G5 ZNY FW.79 X.8 X.06 SAE SPINDLE ASSEMBLY BLADE SPINDLE CS.75-6 X.75 HX G FW.00 X.50 X NT.-8 HX ZY NL FW.4 X.687 X.05/.080H NT.500- NL G PLASTIC WHEEL ASSEMBLY (WITH HARDWARE) CS.500- X 4.5 HX G FW.5 X.06 X.090 SAE PLASTIC WHEEL NT.500- HX JAM ZNYC NOTES:. Used on mowers with serial numbers prior to 060 and higher than 0740; Torque to ft-lbs.. Used on mowers with serial numbers between 060 and Torque the spindle bolt to 8 ft-lbs. 456EX_

102 4" Deck EX_074

103 4" Deck INDEX NO. PART NO. QTY DESCRIPTION DISCHARGE CHUTE 6084 DISCHARGE CHUTE PIN 6084 TORSION SPRING CHUTE BRACKET NT.75-6 HXZY NL FW.406 X.8 X.060 SAE HRD ZN DISCHARGE CHUTE ADAPTOR CB.75-6 X.000 STD CD RS PULLEY COVER LS PULLEY COVER BELT A-SECTION 4." CS.-8 X.750 HX G5 ZN FW.44 X.00 X. HRD Z BLADE, 0.50"-L-F-CW BLADE, F0.50"-L-F-CW 7995 BLADE, 0.50"-CAT-F-CW 7944 BLADE, 0.50"-MUL-F-CW 7940 BLADE, 0.50"-GAT-F-CW CW.6 X.50 X.87 PNT CS.65- X.50 HX G5 ZN NOTES:. Torque to 8 ft-lbs.. Do not torque; the discharge chute must pivot freely. 456EX_

104 46" Service Deck INDEX NO. PART NO. QTY. DESCRIPTION " DECK (WITH DECALS & HARDWARE) CN.-8 X.00 MAX THK 6087 DECK DANGERS NO ROPS DECAL DISCHARGE CHUTE DECAL DECK BELT ROUTING DECAL THROWN OBJECTS DECAL NOTES: EX_074

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106 46" Deck Pulleys & Spindles EX_074

107 46" Deck Pulleys & Spindles INDEX NO. PART NO. QTY DESCRIPTION CS.65- X.500 HX G5 ZNYC 0468 FW.656 X.00 X.078 ZNYC FW.650 X.5 X.8 ZNYCG PULLEY, 5.00" OD IDLER IDLER SLIDE CHAIN DECK LIFT SPRING TENSION SPRING CS.-8X.50 FLT SH ZNYC IDLER SLIDE CS.500- X.50 HX G5 ZN FW.55 X.65 X.5 HD ZY 609 PULLEY, 6.OO" OD FW.00 X.500 X.4 ZN NT.75-6 HX G5 ZN FW.406 X.8 X.060 SAE HRD ZN FW.4 X.687 X.05/.080 HD ZN/YL NT.-8 HX NL ZN CS.75-6 X.75 HX G5 ZN BLADE SPINDLE ASSEMBLY NT.500- HX G8 ZN NY PLASTIC WHEEL ASSEMBLY (WITH HARDWARE) 059 NT.500- HX JAM ZNYC FW.5 X.06 X.090 SAE PLASTIC WHEEL CS.500- X 4.50 HX G5. Torque to ft-lbs. NOTES: 456EX_074 7-

108 46" Deck EX_074

109 46" Deck INDEX NO. PART NO. QTY DESCRIPTION 7784 BELT, A 7" EL 6084 CHUTE PIN 6084 TORSION SPRING DISCHARGE CHUTE NT.75-6 HX G5 ZN NY FW.406 X.8 X.060 SAE CHUTE BRACKET DISCHARGE CHUTE ADAPTER CB.75-6 X.000 STD ZN RS PULLEY COVER 6075 LS PULLEY COVER CS.-8 X.750 HX G5 ZN FW.44 X.00 X. HRD Z BLADE,.50"-L-F-CW BLADE,.50"-MUL-F-CW 7985 BLADE,.50"-GAT-F-CW 6044 BLADE,.50"-CAT-F-CW CW.6 X.50 X.87 PNT CS.65- X.50 HX G5 ZN NOTES:. Torque to 8 ft-lbs.. Do not torque; the discharge chute must pivot freely. 456EX_074 7-

110 54" Service Deck INDEX NO. PART NO. QTY DESCRIPTION " DECK (WITH DECALS & HARDWARE) 7849 BELT ROUTING DECAL 6087 DECK DANGERS DECAL CN.-8 X.00 MAX THK DISCHARGE CHUTE DECAL THROWN OBJECTS DECAL STEP TREAD NOTES: EX_074

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112 54" Deck Pulleys & Spindles EX_074

113 54" Deck Pulleys & Spindles INDEX NO. PART NO. QTY. DESCRIPTION CS.65- X.50 HX G FW.656 X.00 X.078 ZNYC FW.650 X.5 X.8 ZNYC G PULLEY IDLER 5.00" OD IDLER SLIDE TENSION SPRING CHAIN, LINK CS.-8 X.5 FLT SH IDLER SLIDE UHMW CS.500- X.5 HX G5 ZN FW.55 X.65 X.5 HD ZY DRIVE PULLEY 5.68 OP NT.75-6 HX G5 ZNY FW.406 X.8 X.060 SAE CS.75-6 X.75 HX G SPINDLE ASSEMBLY FW.4 X.687 X.05/.080H NT.-8 HX ZY NL NT.500- HX G8 ZY NL PLASTIC WHEEL ASSEMBLY (WITH HARDWARE) FW.5 X.06 X.090 SAE CS.500- X 4.5 HX G PLASTIC WHEEL NT.500- HX JAM ZNYC. Torque to ft-lbs. NOTES: 456EX_

114 54" Deck EX_074

115 54" Deck INDEX NO. PART NO. QTY. DESCRIPTION BELT, B 45.5" EL LS PULLEY COVER RS PULLEY COVER CS.-8 X.750 HX G FW.44 X.00 X. HRD Z DISCHARGE CHUTE TORSION SPRING CHUTE PIN CHUTE BRACKET CHUTE ADAPTER PLATE CB.75-6 X.00 STD CD NT.75-6 HXZY NL FW.406 X.8 X.060 SAE BLADE, 8.50"-L-F-CW BLADE, F8.50"-H-F-CW BLADE, 8.50"-MUL-F-CW 7977 BLADE, 8.50"-GAT-F-CW CW.6.50 X.87 PNT CS.65- X.5 HX G5 Z NT.-8 HXZY NL "A" BLOWOUT BAFFLE CB.-8 X.750 FUL ZN FW.4 X.687 X.05/.080H NOTES:. Torque to 8 ft-lbs.. Do not torque; the discharge chute must pivot freely. 456EX_

116 Deck Lift DETAIL VIEW EX_074

117 Deck Lift INDEX NO. PART NO. QTY. DESCRIPTION NT.75-6 HX GRD 5 ZNY FW.406 X.8 X.060 SAE FW.656 X.50 X.50 ZNY HANDLE, DECK HT LOCK STEERLEVER BUSHING CS.75-6 X.500 HX G PIN, DECK HEIGHT STOP NT.47-4 HX FLG ZN DECK LIFT LINK, NON-SLOT CS.47-4X.750 HX G GREASE FITTING STRAIGHT PIVOT SPACER BUSHING 0644 CS.75-6 X.000 HX G LIFT PEDAL LINK DECK LIFT LINK PULLER STRAP DECK ADJUST PLATE LS (WITH DECAL) DECK HEIGHT DECAL CS.75-6 X.5 HX G5 ZN NT.75-6 HX ZY NL NOTES: 456EX_074 7-

118 Deck Mounting Hardware EX_074

119 Section 8 Seat EX_074 8-

120 Seat EX_074

121 Seat INDEX NO. PART NO. QTY. DESCRIPTION SEAT NT.75-6 HXZY NL FW.406 X.8 X.060 SAE CS.75-6 X.50 HX G5 Z SB.75 X.75 SH NT.-8 HX G5 ZNYC TORSION SPRING SEAT LATCH BATTERY WARNINGS DECAL CS.75-6 X.5 HX G5 ZN 7985 COMPRESSION SPRING.5 X 4.00 X SEAT PAN (WITH DECAL) FW.4 X.687 X.05/.080H CS.-8 X.5 HX G NT.75-6 HX GRD 5 ZNY CS.75-6 X.000 HX G SEAT SWITCH NOTES:. Do not torque; the seat pan and latch must pivot freely. 456EX_074 8-

122 EX_074